Method of forming a concrete building component

ABSTRACT

A building component composed of concrete blocks and a concrete slab with the blocks being recessed along their frontal surfaces for placement within a jig. The concrete receiving surfaces of the blocks are irregular for embedment within the poured concrete. The blocks are in contiguous, surface contact to retain and confine the concrete poured thereon. A method for the face down construction is disclosed.

[151 3,654,742 [451 Apr. 11, 1972 United States Patent Wilnau PTNTEDAPR11 |912 3, 654, 742

snm 1 nr 2 INVENTOR JOHN A. WILNAU PATENTEDAPR 1 l |972 SHEET 2 UF 2NVENTR. JOHN A. wlLNAU BY l AGENT METHOD OF FORMING A CONCRETE BUILDINGCOMPONENT BACKGROUND OF THE INVENTION The present invention relatesgenerally to construction of concrete building components and moreparticularly to a face down constructed component usable as a wall,floor, or ceiling component of a structure and utilizing a concrete slabin combination with contiguous concrete blocks.

For several years concrete or aggregate blocks have been usedsuccessfully in the construction of various types of buildings. Suchblocks characteristically provide certain desirable features bothfunctional and aesthetic, in a structure. The blocks are of a sizepermitting their convenient manual handling for incorporation into thestructure. Such concrete block construction typically requires the useof a matrix or other means for block retention with each block beingindividually set in place. A significant problem with concrete blockbuilding construction is the labor cost factor as each worker, is ofnecessity, a skilled worker.

Other concrete construction has included slab concrete components pouredin place or horizontally for subsequent tilt-up" or transfer to thelocation of the building site. While practical in large structures theconcrete slab requires additional efforts, such as the application of aveneer surface material, to render it attractive.

Efforts to produce suitable building components by a face down method offabrication have not proved acceptable primarily for the reason thatfluid concrete will cause cementing of the blocks to a supportingsurface or spacer material between the blocks. This cementing of theblocks to a supporting surface results from a flow or bleeding of thefluid concrete between the lower surfaces of the blocks and theirsupporting surface. Further, such bleeding on the lower face of theblocks severely detracts from the appearance of the finished wall.

SUMMARY OF THE INVENTION The present invention is embodied within abuilding component and method utilizing both block components and apoured concrete slab the latter integrating the blocks into an integralbuilding component. The component is suitable, functionally andaesthetically, for direct incorporation into a structure. A jig for thebuilding components enables the blocks used to be rapidly set in placeto receive the poured concrete.

More specifically, the blocks are configured along their jig contactingsurfaces to enable simple, accurate locationing in the jig by workmenunskilled in the masonry art. For example, a pair of unskilled workmenmay position, on the present jig, all the block components for an eightfoot by twenty foot building component in less than ten minutes. Thepouring of concrete for completion of the component is preferably' froma pumped source, either a truck if at the construction site or from ahopper at the plant site. The jig facilitates block placement andretention while the blocks placed along the components edges aredesirably of a shape to confine lateral movement of the poured concrete.Alternatively, temporary barriers for the concrete may be utilized.

A novel method is disclosed for the formation of the present buildingcomponent. The method set forth contributes towards a combinedslab-concrete block component of low cost materials and fabrication anda component presenting an attractive exterior requiring no furthermasonry efforts.

Another important object of the invention is to provide a buildingcomponent having the appearance of block construction yet fabricated atsubstantially less cost than conventional block construction. Theresulting component, further, has the structural advantages of a pouredconcrete unit and may be reinforced or pre-stressed similarly to such aunit.

Another object is achieved by the interrelationship of the jig, blocksand poured concrete which respectively serve to accurately locate theblocks with the latter retaining and functioning as a concrete form withthe concrete itself, upon curing, interconnecting the multitude ofconcrete blocks.

Further, the present invention enables the convenient construction ofirregular building components i.e., components other than of solidplanar configuration. The jig and blocks used permit openings to beaccurately formed in the component. Such opening may be for doors,windows, light fixtures, heat vents, etc.

Another object of the invention is to enable the fabrication of aceiling component of a building with the component embodying anattractive relieved surface.

A still further object of the instant invention is to provide blocks ofnovel beveled configuration to retain the poured concrete againstseeping into contact with the jig which would undesirably retardjig-component separation.

BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings:

FIG. 1 is a perspective view of a building component of the presentinvention disposed in an upright position for use as a wall in astructure. l

FIG. 2 is a plan view of an angle iron framework constituting a jig forthe fabrication of the wall of FIG. l,

FIG. 3 is a sectional, elevational view taken along line 3-3 of FIG. 2and showing a fragment of the jig with a block elevated therefrom,

FIG. 4 is a view similar to FIG. 3 taken along line 4-4 of FIG. 2 andshowing an angle iron barrier for concrete applied to the jig adjacent aconcrete block fragment,

FIG. 5 is a perspective view of an intact concrete block usable with thepresent invention and shown prior to halving of the block,

FIG. 6 is a view similar to FIG. 5 showing a second form of an intactblock prior to separation into like halves,

FIG. 7 is an end view of the block of FIG. 5 showing the block aftercutting and after beveling of the edges about the frontal perimeters ofthe resulting blocks,

FIG. 8 is an end view of FIG. 6 showing the block after cutting andafter beveling of the edges about the frontal perimeters of theresulting blocks,

FIG. 9 is a perspective view of the concrete slab side of the presentcomponent,

FIG. 10 is a fragmentary end view of the component of FIG. 9 with asecond component disposed as a wall in place thereon,

FIG. 11 is a fragment of a relief surface attainable with the presentbuilding component, and

FIG. 12 is a sectional view taken along line 12-12 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS With continuing reference tothe accompanying drawings wherein applied reference numerals indicateparts similarly identified in the following specification, the referencenumeral 1 indicates generally the present building component shown as awall but as aforesaid may be in the form of a floor or ceiling member.

The component 1 may be of solid planar shapes or formed with openings asat 2 therein to suit the use to which the component is to be put.Comprising one side surface of the component are a multitude of concreteor aggregate blocks disposed in abutting edge-to-edge relationship. Afirst type of block is indicated at 3, conveniently formed by dividingan intact cast block of the type shown in FIG. 5. A second type of blockis indicated at 4. For purposes of economy of manufacture it has beenfound desirable to cast the blocks as shown in FIGS. 5 and 6 with eachblock therein shown ultimately separated into two blocks prior tobecoming a part of the present component. The planes of separation PSfor the blocks in FIGS. 5 and 6 are shown in broken lines with theplanes for the latter being offset to provide an extended end portion.

With regard to each block 3, and subsequent to its separation, anexterior or frontal surface is indicated at 5 while on the inner orconcrete receiving side at 6 are formed ribs 7 undercut for concreteretention. The ribs 7 have a common bridging portion of reduced size forease of cutting the intact block. About the perimeter of the blocksexterior frontal surface is a recessed area in the form of a continuousbevel formed as at 8 (broken lines in FIG. 5).

Each of the blocks 4, as formed by separation of the intact block shownin FIG. 6, includes an exterior frontal surface l0. End portions 11 andl2 of the block are each undercut on the blocks side 9 whereat anundercut rib 13 is also formed. The extended end portion 11 of eachblock 4 serves to confine the poured concrete when in place on the jigas later elaborated upon. In similarity to the first described blocks 3the perimeter of each block 4 is recessed and is shown as a beveled areaat 14.

The separation of the intact blocksin FIGS. 5 and 6 may be done onconventional block cutting equipment prior to sizing of the blocks bygrinding to exact size and beveling the surfaces at 8 and 14 all ofwhich is done by conventional block grinding equipment. Since thebeveled surfaces of the two blocks 3 and 4 are used for placement on thejig as later described the grinding of the blocks to size and thebeveling grinding must be precisely done. It is desirable to cast theblocks somewhat oversize with reduction to the final dimensions and thebevels being done last by grinding.

The jig, as best shown in FIG. 2, is a latticed framework formed ofwelded right angle stock having stringers at 16 with interfitting stocksections 17 welded in place coplanar with the stringers 16. By way ofexample only, the stringers and sections may be assembled on 16 inchcenters with the upwardly directed ridges of each stringer and sectionbeing so spaced from its adjacent like member. For use in such a jigwith such centers the blocks 3 and 4 would have frontal surfaces at 5and l respectively of 8 by 16 inches. Such an arrangement permits varousdesigns to be worked simply by varying block placement as is shown inFIG. l. Obviously single blocks of a larger size or more than two blocksmay be used depending on the spacing of the jigs stringers and sectionsand the block surface dimensions.

The blocks 3 and 4 rest upon their supporting angle stringers andsections with its longest dimension equal to the distance intermediatethe centers of adjacent stringers or sections. The beveled areas 8 and14 are of complimentary inclination to that of the supporting flange ofthe section or stringer. Placement of the blocks 3 and 4 hence requiresno masonry skill to assure accurate, juxtaposed placement of the blocks.Further, each opening at 18 in the jig may be numbered by a subjacentplacard on the surface below the jig with a correspondingly numbereddiagram being provided to the workman with door and window openingsidentified thereon which are left desired of blocks.

A further variable is provided for by the use of a positionable barrier,shown in the form of a detachable angle iron 20 in FIGS. 2 and 4. Theangle iron is securable to the jig by a clamp 23 to provide a barrier tothe poured concrete when the blocks 3 are used along an edge of thecomponent. In the wall shown in FIGS. 1 and 9 the upper and lower edgesand opening 2 are defined by the blocks 4 in which case the extended endportions 11 thereof functions as a concrete barrier during pouring. Thevertical edges of the component as shown in FIG. l are defined by theends of blocks 3 with the concrete slab at 19 having been poured and setagainst one of the detachable barriers 20 as shown in FIG. 4.

The jig is preferably mounted in place horizontally on crosswise andlengthwise extending I-beams 21,22 to prevent flexing. For fabricationof pre-stressed components the jig may be slightly longitudinallyarched. Further the present component lends itself` to pre-tensioning orpost-tensioning in the conventional manner as done with poured concreteslabs. Weight reducing voids 23 are applicable as are the reinforcingrods 24.

Further, as shown in FIG. 9, plates 25,26 may be located in the fluidconcrete to facilitate attachment of components l by welding. Ifdesired, for aesthetic purposes, some blocks may be unbeveled and thuswill not set into the jig to effect a relieved surface on the completecomponent as shown in FIG. 10.

Having thus described the invention what I desire to secure under aLetters Patent is:

1. A face down method of constructing a concrete-concrete block buildingwall component of' rectangular configuration, said method comprising thesteps of,

sizing of a multitude of concrete blocks by grinding each of thevertical side surfaces of said blocks, each of the blocks having anirregular upper surface thereon,

' forming inwardly directed beveled surfaces about the lowerperimetrical edge of said concrete blocks,

contiguously depositing said blocks upon a rectangular wall sized jigwith the irregular upper surface of the block facing upward, said jigcomprised of latticed angle iron sections with the blocks placed thereonso as to locate their beveled surfaces in resting contact upon said jigsections with each vertical surface of an interior block being insurfacial abutment with a like surface on another block, said blockswhen so positioned forming a composite block assemblage impervious topoured fluid concrete, and

pouring concrete over said blocks to fully cover same to form amonolithic concrete slab which upon curing results in an integralconcrete-concrete block building wall component.

2. The face down method of constructing a concreteconcrete blockbuilding wall component as claimed in claim 1 including the additionalstep accomplished prior to pouring of concrete consisting in themounting of a detachable barrier to the jig in abutment with the alignedsurfaces of a row of blocks along an edge of the wall component beingconstructed to confine the fluid concrete when poured.

3. The face down method of constructing a concreteconcrete blockbuilding wall component as claimed in claim 1 wherein the multitude ofblocks include those having extended end portions of greater verticaldimension than the remaining concrete blocks, the additional step ofdepositing the blocks having extended end portions along an edge of thewall component to confine the fluid concrete when poured.

4. The face down method of constructing a concreteconcrete blockbuilding wall component as claimed in claim 1 including the additionalstep of selectively depositing said blocks upon the latticed jigaccording to a predetermined plan so as to leave areas of the jig devoidof said blocks with the void areas defining door and window openings inthe wall component.

5. The face down method of constructing a concreteconcrete bl`ockbuilding wall component as claimed in claim 4 including the additionalstep accomplished prior to pouring of concrete consisting in themounting of a detachable barrier to the jig in abutment with the alignedsurfaces of a row of rblocks along an edge of the wall component toconfine the fluid concrete when poured.

6. The face down method of constructing a concreteconcrete blockbuilding wall component as claimed in claim 5 wherein the multitude ofblocks include those having extended end portions of greater verticaldimension than the remaining blocks, the additional step of depositingblocks having extended end portions along an edge of the wall componentto confine the fluid concrete when poured.

1. A face down method of constructing a concrete-concrete block buildingwall component of rectangular configuration, said method comprising thesteps of, sizing of a multitude of concrete blocks by grinding each ofthe vertical side surfaces of said blocks, each of the blocks having anirregular upper surface thereon, forming inwardly directed beveledsurfaces about the lower perimetrical edge of said concrete blocks,contiguously depositing said blocks upon a rectangular wall sized jigwith the irregular upper surface of the block facing upward, said jigcomprised of latticed angle iron sections with the blocks placed thereonso as to locate their beveled surfaces in resting contact upon said jigsections with each vertical surface of an interior block being insurfacial abutment with a like surface on another block, said blockswhen so positioned forming a composite block assemblage impervious topoured fluid concrete, and pouring concrete over said blocks to fullycover same to form a monolithic concrete slab which upon curing resultsin an integral concrete-concrete block building wall component.
 2. Theface down method of constructing a concrete-concrete block building wallcomponent as claimed in claim 1 including the additional stepaccomplished prior to pouring of concrete consisting in the mounting ofa detachable barrier to the jig in abutment with the aligned surfaces ofa row of blocks along an edge of the wall component being constructed toconfine the fluid concrete when poured.
 3. The face down method ofconstructing a concrete-concrete block building wall component asclaimed in claim 1 wherein the multitude of blocks include those havingextended end portions of greater vertical dimension than the remainingconcrete blocks, the additional step of depositing the blocks havingextended end portions along an edge of the wall component to confine thefluid concrete when poured.
 4. The face down method of constructing aconcrete-concrete block building wall component as claimed in claim 1including the additional step of selectively depositing said blocks uponthe latticed jig according to a predetermined plan so as to leave areasof the jig devoid of said blocks with the void areas defining door andwindow openings in the wall component.
 5. The face down method ofconstructing a concrete-concrete block building waLl component asclaimed in claim 4 including the additional step accomplished prior topouring of concrete consisting in the mounting of a detachable barrierto the jig in abutment with the aligned surfaces of a row of blocksalong an edge of the wall component to confine the fluid concrete whenpoured.
 6. The face down method of constructing a concrete-concreteblock building wall component as claimed in claim 5 wherein themultitude of blocks include those having extended end portions ofgreater vertical dimension than the remaining blocks, the additionalstep of depositing blocks having extended end portions along an edge ofthe wall component to confine the fluid concrete when poured.